INCREASING EFFICIENCY OF REPAIRING, MANUFACTURING AND OPERATION OF THE TPP FACILITIES BY TECHNOLOGY OF GAS-THERMAL COATING AND LASER SURFACE MELTING

The article considers effectiveness increase of the TPP heat-mechanical equipment repair, manufacturing and maintenance as exemplified by gas-thermal technique for hardening laststages rotor blades of the steam turbines. The rotor blades work under conditions of intense power loading, their airfoil being erosion-corrosion destructed by the action of the moist-steam flow. Repairing companies employ quite a number of technologies to restore some of erosion-worn rotor blades. Inter alia, argon-arc, plasma and gas-powder weld deposition of the original material with subsequent machining, stellite protection recovery, electrical spark alloying the entry edge mat surface, spraying ion-plasma coating on the blade airfoil surface. In domestic turbine building, rotor blades of the steam turbines last stages are manufactured of martensitic class stainless steel. The key condition for successful blade restoration is thermal effect minimizing on the base material for excluding the slag areas possible forming. The laser surface coating technology provides these conditions. They coat the surface of an item being processed by way of melting the base and the adding material. In as much the base melts smallest, the coating characteristics depend mainly on the properties of adding material. The procedure of laser coating passes through several stages including physical contact creation, chemical interaction (laser radiation absorption), volumetrical processes resulting in formation of stable bonds in volume of the materials that have reacted. For the low-pressure cylinder rotor blades supplementary protection against erosion destruction, LLC ‘Technological Systems of Protective Coating’ developed technology of the blade airfoil protective finish by method of high-speed gas-flame sputter. The company realized this technology in 2012 during K-200-12,8 turbine (of the Leningrad Metallurgical Works – LMZ) repairing in Zainsk SDPP by JSC ‘Tatenergo’. The feature of the technology is performing the rotor blade airfoil surface hardening without extracting the rotor out of the low-pressure cylinder and with rotor blades remaining on the rotor. According the SDPP data, as for the beginning of 2015 there are no traces of the rotor blade erosive wear detected. 

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